EP3406382B1 - Composite component having angled braze joint and coupon brazing method - Google Patents
Composite component having angled braze joint and coupon brazing method Download PDFInfo
- Publication number
- EP3406382B1 EP3406382B1 EP18173747.9A EP18173747A EP3406382B1 EP 3406382 B1 EP3406382 B1 EP 3406382B1 EP 18173747 A EP18173747 A EP 18173747A EP 3406382 B1 EP3406382 B1 EP 3406382B1
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- Prior art keywords
- main body
- coupon
- angled
- slot
- interface
- Prior art date
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Images
Classifications
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- G06F30/20—Design optimisation, verification or simulation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
- B23K1/0018—Brazing of turbine parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/19—Soldering, e.g. brazing, or unsoldering taking account of the properties of the materials to be soldered
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
- B23K20/021—Isostatic pressure welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K3/00—Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
- B23K3/08—Auxiliary devices therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P13/00—Making metal objects by operations essentially involving machining but not covered by a single other subclass
- B23P13/02—Making metal objects by operations essentially involving machining but not covered by a single other subclass in which only the machining operations are important
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
- B23P6/005—Repairing turbine components, e.g. moving or stationary blades, rotors using only replacement pieces of a particular form
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
- F01D25/28—Supporting or mounting arrangements, e.g. for turbine casing
- F01D25/285—Temporary support structures, e.g. for testing, assembling, installing, repairing; Assembly methods using such structures
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/005—Repairing methods or devices
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- G06F30/17—Mechanical parametric or variational design
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
- B23K2103/26—Alloys of Nickel and Cobalt and Chromium
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2230/00—Manufacture
- F05D2230/20—Manufacture essentially without removing material
- F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
- F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
- F05D2230/237—Brazing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2250/00—Geometry
- F05D2250/20—Three-dimensional
- F05D2250/23—Three-dimensional prismatic
- F05D2250/232—Three-dimensional prismatic conical
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2113/00—Details relating to the application field
- G06F2113/26—Composites
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/06—Power analysis or power optimisation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the subject matter disclosed herein relates to manufacturing and repair of components. More specifically, the subject matter disclosed herein relates to approaches of manufacturing and/or repairing components using brazing techniques.
- Metal alloys can be particularly useful in industrial applications.
- metal alloys are commonly used to form components within industrial machinery subjected to high temperatures, pressures and/or stresses over extended periods.
- Systems such as turbomachines, dynamoelectric machines, fuel flow systems, aviation systems, etc. employ metal alloys in their parts.
- components may require maintenance and/or repair, which may present particular challenges in the case of metal alloys.
- brittle metal alloys or high-gamma prime alloys can be structurally compromised when subject to particular types of heat treatment such as welding. This can make repair and maintenance of components formed from these alloys particularly challenging. Additionally, forming composite parts with these types of alloys can be disadvantageous.
- a damaged portion of a superalloy material turbine blade body is removed, forming an excavated recess.
- a repair splice is formed of a same material with similar mechanical structural properties, having a mating outer profile conforming to the corresponding recess profile.
- the repair splice is inserted and captured within the recess, so that the blade body and repair splice are mechanically interlocked.
- Given similarities in mechanical properties of both the blade body and the mechanically interlocked splice the repaired blade's overall mechanical structural properties are similar to those of an undamaged blade.
- the repair splice is affixed to the blade body so that the interlocking respective portions of each do not separate.
- US 2003/034379 forms the basis for the preamble of claims 1 and 9 and suggests a method of repairing cracks, imperfections, and the like in a cast article of superalloy composition having a directionally oriented microstructure and growth axis.
- Such plug further possesses an inner end, an outer end, and a surface therebetween.
- the plug is inserted into the aperture whereby the plug growth axis is oriented in alignment with the article growth axis.
- Bonding material is applied between the surfaces of the plug and the aperture, before or after insertion of the plug into the aperture.
- the article is thereafter heated such that the bonding material joins the surface of the plug and the aperture.
- the outer end of the plug thereafter is polished so that such outer end is approximately level with the article's outer wall.
- the process can include creating a frame of reference between the plug and the aperture, such that the growth axis of the plug's second directional microstructure can be aligned with the first growth axis of the article's first directional microstructure upon insertion of the plug into the aperture.
- a plug made in accordance with the aforesaid method is further disclosed and claimed.
- US 6,413,650 discloses a method of repairing cracks, imperfections, and the like in a cast article.
- a frusto-conical aperture is created in the article in the location of the crack or imperfection.
- a mating tapered plug is prepared such that the tapered plug can fit into the aperture so that the sloped side walls of the tapered plug evenly and unilaterally rest on frusto-conical sides of the aperture.
- the tapered plug is disposed into the aperture, and bonding material is applied between the surfaces of the tapered plug and the aperture, before or after insertion of the tapered plug into the aperture.
- the article is thereafter heated such that the bonding material joins the surfaces of the tapered plug and the aperture.
- the outer end of the tapered plug thereafter is polished so that such outer end is approximately level with the article's outer side in a refinement of the invention, the plug member may be pushed into the aperture such that a controlled interference fit is produced.
- a hole formed in a superalloy turbine blade is sealed by providing a superalloy plug, machining the hole to be of a configuration can receive the plug therein, and bonding the plug to the turbine blade.
- the plug can be of a threaded or unthreaded configuration and can be of a tapered or straight configuration.
- the plug is bonded to the hole by applying a bonding catalyst to one or both of the plug and the hole or by positioning the bonding catalyst therebetween, and providing appropriate treatment to the bonding catalyst, such as heating or other treatment, to cause the bonding catalyst to form a bond between the plug and the turbine blade to form a joint therebetween. Any of a variety of known bonds can be employed to form the joint.
- the plug additionally may be pre-cooled prior to insertion thereof into the hole in the turbine blade, or alternatively may be of a coefficient of thermal expansion that is greater than that of the turbine blade.
- the subject matter disclosed herein relates to manufacturing and/or repair. More specifically, the subject matter disclosed herein relates to approaches for forming composite components including metal alloys, also known as Shear Enabled Regionally Engineered Facets (SEREF).
- SEREF Shear Enabled Regionally Engineered Facets
- various aspects of the disclosure include a composite metal component, and methods of forming such a component.
- the composite metal component has a main body and a coupon filling a slot in the main body, and the interface between the main body and the coupon is an angled braze joint.
- the angled interface between the main body and the coupon as opposed to a substantially normal interface in conventional composite components, can transfer the tensile stress applied at that interface to predominately shear stress.
- the composition of metal alloys in particular, high-gamma prime alloys or other brittle alloys, gives these materials significantly greater shearing strength than tensile strength. As such, these composite components may be stronger than conventional composite components formed with normal braze joints between a main body and a coupon.
- the angle of the interface between the main body and the coupon is approximately 10-25 degrees (measured from surface plane). In other embodiments, the angle of the interface between the main body and the coupon is approximately 25-35 degrees, and in other cases it is between approximately 35-45 degrees. In various embodiments, the angle of the interface between the main body and the coupon is defined by an equation which accounts for the surface area of the interface, the angle of the interface, and the thickness of the wall of the main body and the coupon proximate the joint.
- the composite component can include a refurbished component, e.g., where the main body is an original part having gone through field use and the coupon is a replacement portion of the component.
- the composite component can include two original parts (either having gone through field use, or not) joined at an interface, and in other cases, the composite component can include two replacement parts joined at an interface.
- FIG. 1 shows a schematic depiction of a metal alloy component 10 and a coupon 20 for coupling with metal alloy component 10.
- FIG. 2 shows metal alloy component 10 and coupon 20 coupled to form a composite component 30. Also shown in FIG. 2 is a braze joint 40 (portions shown), coupling metal alloy component 10 and coupon 20 at an interface (further described herein). It is understood that braze joint 40 can extend across an entirety of the interface between metal alloy component 10 and coupon 20, or in some cases, may extend only partially across that interface.
- composite component 30 can include metal alloy component 10, which has a main body 50 formed of a metal alloy.
- the metal alloy can include a brazeable alloy, such as a high-gamma prime alloy or a brittle alloy.
- alloys having a gamma prime percentage greater than 40% can be well suited for approaches according to various embodiments of the disclosure, as these alloys can present challenges in welding.
- Examples are gamma prime ( ⁇ ') precipitation-strengthened nickel-base superalloys, particular examples of which can include René 125, René 80, René N5, René N4, René 108, GTD-111TM, GTD-444TM, Inconel (IN)738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, and PWA1484.
- Each of these alloys has a relatively high gamma prime (principally Ni3(Al,Ti)) content as a result of containing significant amounts of aluminum and/or titanium.
- coupon 20 includes the same metal alloy as metal alloy component 10, or a distinct metal alloy.
- the coupon 20 can include a metal alloy which is more ductile than the alloy in metal alloy component 10.
- coupon 20 can be formed of (single-crystal, or SD) René N5, (directionally solidified, or DS) René 108, and/or (N4) or (Equiaxed, or EA) René 108.
- main body 50 can have a wall 60 with an inner surface 70 and an (opposed) outer surface 80.
- inner surface 70 and outer surface 80 are merely indicative that these are distinct surfaces proximate braze joint 40 and coupon 20, as the terms “inner” and “outer” are not intended to be limiting.
- Main body 50 can also include a slot 90 extending at least partially through wall 60 (shown extending entirely through wall 60 in example depiction of FIG. 1 ). As shown in FIG. 1 , slot 90 can include an angled main body interface (face) 100 in wall 60, described further herein.
- Composite component 30 includes coupon 20 coupled with slot 90, where coupon 20 has an angled coupon interface (face) 110 that complements angled main body interface 100.
- Angled coupon interface (face) 110 can span between an outer surface 120 and an inner surface 130 of coupon 20.
- the angle of angled coupon interface 110 is equal or approximately (e.g., within margin of measurement error) equal with the angle of angled main body interface 100, both referred to as angle ( ⁇ ), as measured from a plane (P) coincident with outer surface 80 of main body 50.
- coupon 20 can have a taper, such that it has a larger dimension (LD) spanning slot 90 across outer surface 80, and a smaller dimension (SD) spanning slot 90 across inner surface 70.
- angle ( ⁇ ) is between approximately 10 degrees and approximately 60 degrees. However, in other particular embodiments, angle ( ⁇ ) is between approximately 10 degrees and approximately 25 degrees. In other cases, angle ( ⁇ ) is between approximately 25-35 degrees, and in other cases angle ( ⁇ ) is between approximately 35-45 degrees. As noted herein, the angle ( ⁇ ) is designed for these particular metal alloys such that proximate braze joint 40, angled main body interface 100 and angled coupon interface 110 are configured to bear a predominately shear stress in response to application of tension on composite component 30. In some cases, composite component 30 can include a turbomachine component, such as a combustion component or a gas or steam turbine component.
- a turbomachine component such as a combustion component or a gas or steam turbine component.
- FIG. 3 shows a flow diagram illustrating processes in a method according to various embodiments.
- FIGS. 4 and 5 illustrate some of the processes described with reference to FIG. 3 .
- a method can include:
- Process P1 forming slot 90 in main body 50 of a metal alloy component 10, where slot 90 is formed to extend at least partially through wall 60 ( FIGS. 4 and 5 ).
- forming slot 90 includes forming angled main body interface 100 in wall 60.
- metal alloy component 10 can include a previously commissioned component exposed to operation within a machine, e.g., a turbomachine, dynamoelectric machine or other machine.
- metal alloy component 10 includes a turbine bucket, blade or nozzle. It is understood that metal alloy component 10 can include any machine component, in any of a variety of industrial or other machines subjected to high temperatures and/or pressures, e.g., turbomachines, dynamoelectric machines, or engine systems.
- metal alloy component 10 can include an original equipment component not yet deployed in operation.
- forming slot 90 in main body 50 includes cutting metal alloy component 10, e.g., with a saw or other machining tool.
- metal alloy component 10 can be formed as an original component, including slot 90, via conventional molding, casting, etc., or via additive manufacturing techniques further described herein.
- Process P2 forming coupon 20 for coupling with slot 90 in metal alloy component 10, where coupon 20 is formed having angled coupon interface 110 that complements angled main body interface 100 in metal alloy component 10 (coupon 20 shown in FIG. 1 ).
- coupon 20 is formed by casting or other conventional manufacturing techniques, and in other embodiments, coupon 20 is formed by additive manufacturing techniques further described herein.
- coupon 20 includes a metal alloy, e.g., a metal alloy similar to the composition of metal alloy component 10, or a distinct metal alloy.
- angled main body interface 100 and angled coupon interface 110 is formed to have angle ( ⁇ ) between approximately 10 degrees and approximately 45 degrees, as measured from plane (P) coincident with outer surface 80 of main body 50.
- coupon 20 and slot 90 can be formed to have a range of angles ( ⁇ ), larger dimensions (LD) and smaller dimensions (SD), depending upon the thickness (Z) of wall 60.
- dimensions (LD, SD) will be dictated in part by a portion of metal alloy component 10 which requires repair. For example, where metal alloy component 10 is in need of repair, a portion of metal alloy component 10 is removed (e.g., cut out), and slot 90 is formed to accommodate coupon 20. In these cases, the dimensions of diameters, along with thickness (Z) of wall 60, will limit the range of interface angles ( ⁇ ).
- this process can include brazing coupon 20 to main body 50 at slot 90 to form composite component 30 ( FIG. 2 ).
- conventional brazing techniques can be used to form braze joint 40 along angled main body interface 100 and angled coupon interface 110.
- the brazing temperature may range between approximately 925 degrees Celsius (C) (approximately 1700 degrees Fahrenheit (F)) and 1260 degrees C (approximately 2300 degrees F). In some particular cases, the brazing temperature may range between approximately 1065 degrees C (approximately 1950 degrees F) and approximately 1230 degrees F (approximately 2250 degrees F).
- the thickness of the braze joint can be between approximately 0.0025 millimeters (mm) (approximately 0.1 mils) and approximately 1.27 millimeters (approximately 0.05 inches or approximately 2 mils). In some particular cases, the thickness of the braze joint can be approximately 0.025 millimeters (mm) (approximately 1 mil) to approximately 0.1 mm (approximately 4 mils).
- the angled main body interface 100 and angled coupon interface 110, proximate are configured to bear a predominately shear stress in response to application of tension on composite component 30.
- an additional process can include performing a hot isostatic pressure (HIP) heat treatment (HT) on composite component 30.
- HIP hot isostatic pressure
- This HIP HT can occur after brazing coupon 20 to main body 50 at slot 90.
- This HIP HT can include any conventional HIP process known in the art, including the use of an inert gas (e.g., argon) at an elevated temperature (e.g., up to approximately 1,400 degrees C) and pressure (e.g., up to approximately 300 mega-pascals (MPa)) to reduce the porosity/increase the density of composite component 30.
- an inert gas e.g., argon
- pressure e.g., up to approximately 300 mega-pascals (MPa)
- composite component 30 in FIGS. 1 and 2 shows a single coupon 30, it is understood that composite component 30 can include a plurality of coupons 20 which may combine to fill slot 90 according to various embodiments of the disclosure. That is, while a single coupon 20 is shown in FIGS. 1 and 2 , it is understood that two or more coupons 20 can be formed in order to fill slot 90 in composite component 30.
- a pair of coupons e.g., similar to coupon 20
- main body 50 e.g., one from each of inner surface 70 and outer surface 80.
- the pair of coupons could share approximately the same shorter diameter (SD) value, their longer diameter (LD) value may be slightly different due to the geometry of composite component 30.
- SD shorter diameter
- LD longer diameter
- forming slot 90 in main body 50 can include forming one or more slots 90 from two distinct directions through wall 60. That is, in various embodiments, one or more slots 90 may be formed in main body 50 (as described herein) from one or more surfaces (e.g., inner surface 70, outer surface 80). For example, as shown in the schematic depiction of a metal alloy component 210 in FIGS. 6 and 7 , slots 90 can be formed (as described herein) from opposing surfaces (e.g., inner surface 70 and outer surface 80), and a plurality of coupons 20 ( FIG. 6 ) can be formed (as described herein) to couple with slot(s) 90 and form a composite component 230 ( FIG. 8 ). In some cases, two coupons 20 ( FIG.
- Coupons 20 can be coupled with slots 90 as discussed herein to form another embodiment of a composite component.
- those slots 90 may connect to form an aperture 250 through metal alloy component 210, however, in other embodiments, these slots 90 may remain separated by a portion of wall 60.
- distinct slots 90 can have distinct dimensions (e.g., as governed by Equation 1), however, in other cases, distinct slots 90 can be substantially symmetrical with respect to wall 60.
- the larger diameter (LD) can be reduced relative to the larger diameter (LD) in composite component 30, which permits composite component 230 to have a lesser interface angle ( ⁇ ) (relative to composite component 30), while still being configured to bear a predominately shear stress in response to application of tension on composite component 230.
- One or more portions of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ) may be formed in a number of ways.
- at least a portion of composite component 30 may be formed by conventional manufacturing techniques, such as molding, casting, machining (e.g., cutting), etc.
- additive manufacturing is particularly suited for manufacturing at least a portion of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ), e.g., metal alloy component 10, metal alloy component 210 and/or coupon 20.
- additive manufacturing may include any process of producing an object through the successive layering of material rather than the removal of material, which is the case with conventional processes.
- Additive manufacturing can create complex geometries without the use of any sort of tools, molds or fixtures, and with little or no waste material. Instead of machining components from solid billets of metal (e.g., alloy) or other material such as plastics and/or polymers, much of which is cut away and discarded, the only material used in additive manufacturing is what is required to shape the part.
- Additive manufacturing processes may include but are not limited to: 3D printing, rapid prototyping (RP), direct digital manufacturing (DDM), selective laser melting (SLM) and direct metal laser melting (DMLM). In the current setting, DMLM can be beneficial.
- FIG. 9 shows a schematic/block view of an illustrative computerized additive manufacturing system 900 for generating an object 902.
- system 900 is arranged for DMLM.
- Object 902 is illustrated as a double walled turbine element; however, it is understood that the additive manufacturing process can be readily adapted to manufacture at least a portion of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ), e.g., metal alloy component 10, metal alloy component 110 and/or coupon 20.
- AM system 900 generally includes a computerized additive manufacturing (AM) control system 904 and an AM printer 906.
- AM computerized additive manufacturing
- AM system 900 executes code 920 that includes a set of computer-executable instructions defining at least a portion of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ) to physically generate the object using AM printer 906.
- Each AM process may use different raw materials in the form of, for example, fine-grain powder, liquid (e.g., polymers), sheet, etc., a stock of which may be held in a chamber 910 of AM printer 906.
- at least a portion of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ) may be made of metal(s), alloy(s), plastic/polymers or similar materials.
- an applicator 912 may create a thin layer of raw material 914 spread out as the blank canvas from which each successive slice of the final object will be created.
- applicator 912 may directly apply or print the next layer onto a previous layer as defined by code 920, e.g., where the material is a polymer.
- a laser or electron beam 916 fuses particles for each slice, as defined by code 920, but this may not be necessary where a quick setting liquid plastic/polymer is employed.
- Various parts of AM printer 906 may move to accommodate the addition of each new layer, e.g., a build platform 918 may lower and/or chamber 910 and/or applicator 912 may rise after each layer.
- AM control system 904 is shown implemented on computer 930 as computer program code.
- computer 930 is shown including a memory 932, a processor 934, an input/output (I/O) interface 936, and a bus 938. Further, computer 930 is shown in communication with an external I/O device/resource 940 and a storage system 942.
- processor 934 executes computer program code, such as AM control system 904, that is stored in memory 932 and/or storage system 942 under instructions from code 920 representative of at least a portion of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ), described herein.
- processor 934 can read and/or write data to/from memory 932, storage system 942, I/O device 940 and/or AM printer 906.
- Bus 938 provides a communication link between each of the components in computer 930, and I/O device 940 can comprise any device that enables a user to interact with computer 940 (e.g., keyboard, pointing device, display, etc.).
- Computer 930 is only representative of various possible combinations of hardware and software.
- processor 934 may comprise a single processing unit, or be distributed across one or more processing units in one or more locations, e.g., on a client and server.
- memory 932 and/or storage system 942 may reside at one or more physical locations.
- Memory 932 and/or storage system 942 can comprise any combination of various types of non-transitory computer readable storage medium including magnetic media, optical media, random access memory (RAM), read only memory (ROM), etc.
- Computer 930 can comprise any type of computing device such as a network server, a desktop computer, a laptop, a handheld device, a mobile phone, a pager, a personal data assistant, etc.
- Additive manufacturing processes begin with a non-transitory computer readable storage medium (e.g., memory 932, storage system 942, etc.) storing code 920 representative of at least a portion of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ).
- code 920 includes a set of computer-executable instructions defining outer electrode that can be used to physically generate the tip, upon execution of the code by system 900.
- code 920 may include a precisely defined 3D model of outer electrode and can be generated from any of a large variety of well-known computer aided design (CAD) software systems such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc.
- CAD computer aided design
- code 920 can take any now known or later developed file format.
- code 920 may be in the Standard Tessellation Language (STL) which was created for stereolithography CAD programs of 3D Systems, or an additive manufacturing file (AMF), which is an American Society of Mechanical Engineers (ASME) standard that is an extensible markup-language (XML) based format designed to allow any CAD software to describe the shape and composition of any three-dimensional object to be fabricated on any AM printer.
- STL Standard Tessellation Language
- AMF additive manufacturing file
- ASME American Society of Mechanical Engineers
- XML extensible markup-language
- Code 920 may be translated between different formats, converted into a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as necessary.
- Code 920 may be an input to system 900 and may come from a part designer, an intellectual property (IP) provider, a design company, the operator or owner of system 900, or from other sources.
- IP intellectual property
- AM control system 904 executes code 920, dividing at least a portion of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ) into a series of thin slices that it assembles using AM printer 906 in successive layers of liquid, powder, sheet or other material.
- each layer is melted to the exact geometry defined by code 920 and fused to the preceding layer.
- the portion(s) of composite component 30 ( FIG. 2 ) and/or composite component 230 ( FIG. 8 ) may be exposed to any variety of finishing processes, e.g., minor machining, sealing, polishing, assembly to other part of the igniter tip, etc.
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Description
- The subject matter disclosed herein relates to manufacturing and repair of components. More specifically, the subject matter disclosed herein relates to approaches of manufacturing and/or repairing components using brazing techniques.
- Metal alloys can be particularly useful in industrial applications. For example, metal alloys are commonly used to form components within industrial machinery subjected to high temperatures, pressures and/or stresses over extended periods. Systems such as turbomachines, dynamoelectric machines, fuel flow systems, aviation systems, etc. employ metal alloys in their parts. During the lifespan of these systems, components may require maintenance and/or repair, which may present particular challenges in the case of metal alloys. For example, brittle metal alloys or high-gamma prime alloys can be structurally compromised when subject to particular types of heat treatment such as welding. This can make repair and maintenance of components formed from these alloys particularly challenging. Additionally, forming composite parts with these types of alloys can be disadvantageous.
According to the teaching ofUS 2013/115091 a damaged portion of a superalloy material turbine blade body is removed, forming an excavated recess. A repair splice is formed of a same material with similar mechanical structural properties, having a mating outer profile conforming to the corresponding recess profile. The repair splice is inserted and captured within the recess, so that the blade body and repair splice are mechanically interlocked. Given similarities in mechanical properties of both the blade body and the mechanically interlocked splice the repaired blade's overall mechanical structural properties are similar to those of an undamaged blade. The repair splice is affixed to the blade body so that the interlocking respective portions of each do not separate. Localized affixation and subsequent cosmetic blade surface repair can be performed with softer, low temperature application braze and weld alloys.
US 2003/034379 forms the basis for the preamble ofclaims 1 and 9 and suggests a method of repairing cracks, imperfections, and the like in a cast article of superalloy composition having a directionally oriented microstructure and growth axis. An aperture, usually frustois created in the article in the location of the crack or imperfection. A plug, having a second directionally oriented microstructure having a directional microstructure with a growth axis and a superalloy composition substantially identical to the article superalloy composition, is created. Such plug further possesses an inner end, an outer end, and a surface therebetween. The plug is inserted into the aperture whereby the plug growth axis is oriented in alignment with the article growth axis. Bonding material is applied between the surfaces of the plug and the aperture, before or after insertion of the plug into the aperture. The article is thereafter heated such that the bonding material joins the surface of the plug and the aperture. The outer end of the plug thereafter is polished so that such outer end is approximately level with the article's outer wall. The process can include creating a frame of reference between the plug and the aperture, such that the growth axis of the plug's second directional microstructure can be aligned with the first growth axis of the article's first directional microstructure upon insertion of the plug into the aperture. A plug made in accordance with the aforesaid method is further disclosed and claimed.
US 6,413,650 discloses a method of repairing cracks, imperfections, and the like in a cast article. A frusto-conical aperture is created in the article in the location of the crack or imperfection. A mating tapered plug is prepared such that the tapered plug can fit into the aperture so that the sloped side walls of the tapered plug evenly and unilaterally rest on frusto-conical sides of the aperture. The tapered plug is disposed into the aperture, and bonding material is applied between the surfaces of the tapered plug and the aperture, before or after insertion of the tapered plug into the aperture. The article is thereafter heated such that the bonding material joins the surfaces of the tapered plug and the aperture. The outer end of the tapered plug thereafter is polished so that such outer end is approximately level with the article's outer side in a refinement of the invention, the plug member may be pushed into the aperture such that a controlled interference fit is produced.
According toUS 6,454,156 a hole formed in a superalloy turbine blade is sealed by providing a superalloy plug, machining the hole to be of a configuration can receive the plug therein, and bonding the plug to the turbine blade. The plug can be of a threaded or unthreaded configuration and can be of a tapered or straight configuration. The plug is bonded to the hole by applying a bonding catalyst to one or both of the plug and the hole or by positioning the bonding catalyst therebetween, and providing appropriate treatment to the bonding catalyst, such as heating or other treatment, to cause the bonding catalyst to form a bond between the plug and the turbine blade to form a joint therebetween. Any of a variety of known bonds can be employed to form the joint. The plug additionally may be pre-cooled prior to insertion thereof into the hole in the turbine blade, or alternatively may be of a coefficient of thermal expansion that is greater than that of the turbine blade. - The present disclosure relates to the subject matter set forth in the claims.
- In another aspect not being herein claimed the disclosure relates to a non-transitory computer readable storage medium storing code representative of at least a portion of a composite component, the at least a portion of the composite component physically generated upon execution of the code by a computerized additive manufacturing system, the code including: code representing at least the portion of the composite component, the composite component including: a metal alloy component including a main body, the main body having: a wall having an inner surface and an outer surface; and a slot extending at least partially through the wall, the slot including an angled main body interface in the wall; a coupon coupled with the slot, the coupon having an angled coupon interface complementing the angled main body interface, wherein the coupon has a larger diameter (LD) spanning the slot across the outer surface of the main body; and a smaller diameter (SD) spanning the slot across an inner surface of the main body, wherein the LD is defined by: LD = ((2∗Z)/tan α) + SD wherein Z = a thickness of the wall and α = an angle of the angled main body interface and the angled coupon interface, as measured from a plane coincident with the outer surface of the main body; and a braze joint coupling the coupon to the main body at the slot.
- These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure, in which:
-
FIG. 1 is a schematic depiction of separated portions of a composite component according to various embodiments of the disclosure. -
FIG. 2 is a schematic depiction of an assembled composite component according to various embodiments of the disclosure. -
FIG. 3 is a flow diagram illustrating processes in forming a composite component according to various embodiments of the disclosure. -
FIG. 4 shows a metal alloy component prior to a process performed according to various embodiments of the disclosure. -
FIG. 5 shows the metal alloy component ofFIG. 4 after forming a slot according to various embodiments of the disclosure. -
FIG. 6 is a schematic depiction of separated portions of a composite component according to various embodiments of the disclosure. -
FIG. 7 shows a distinct schematic view of a portion of the composite component ofFIG. 6 . -
FIG. 8 is a schematic depiction of an assembled composite component according to various embodiments of the disclosure. -
FIG. 9 shows a block diagram of an additive manufacturing process including a non-transitory computer readable storage medium storing code representative of one or more portions of the composite component ofFIG. 2 . - It is noted that the drawings of the disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the disclosure, and therefore should not be considered as limiting the scope of the disclosure.
In the drawings, like numbering represents like elements between the drawings. - The subject matter disclosed herein relates to manufacturing and/or repair. More specifically, the subject matter disclosed herein relates to approaches for forming composite components including metal alloys, also known as Shear Enabled Regionally Engineered Facets (SEREF).
- In contrast to conventional approaches, various aspects of the disclosure include a composite metal component, and methods of forming such a component. In various embodiments, the composite metal component has a main body and a coupon filling a slot in the main body, and the interface between the main body and the coupon is an angled braze joint. The angled interface between the main body and the coupon, as opposed to a substantially normal interface in conventional composite components, can transfer the tensile stress applied at that interface to predominately shear stress. The composition of metal alloys, in particular, high-gamma prime alloys or other brittle alloys, gives these materials significantly greater shearing strength than tensile strength. As such, these composite components may be stronger than conventional composite components formed with normal braze joints between a main body and a coupon.
- In some particular cases, the angle of the interface between the main body and the coupon is approximately 10-25 degrees (measured from surface plane). In other embodiments, the angle of the interface between the main body and the coupon is approximately 25-35 degrees, and in other cases it is between approximately 35-45 degrees. In various embodiments, the angle of the interface between the main body and the coupon is defined by an equation which accounts for the surface area of the interface, the angle of the interface, and the thickness of the wall of the main body and the coupon proximate the joint.
- In various embodiments, the composite component can include a refurbished component, e.g., where the main body is an original part having gone through field use and the coupon is a replacement portion of the component. In other cases, the composite component can include two original parts (either having gone through field use, or not) joined at an interface, and in other cases, the composite component can include two replacement parts joined at an interface.
- In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific embodiments in which the present teachings may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the present teachings and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present teachings. The following description is, therefore, merely illustrative.
-
FIG. 1 shows a schematic depiction of ametal alloy component 10 and acoupon 20 for coupling withmetal alloy component 10.FIG. 2 showsmetal alloy component 10 andcoupon 20 coupled to form acomposite component 30. Also shown inFIG. 2 is a braze joint 40 (portions shown), couplingmetal alloy component 10 andcoupon 20 at an interface (further described herein). It is understood that braze joint 40 can extend across an entirety of the interface betweenmetal alloy component 10 andcoupon 20, or in some cases, may extend only partially across that interface. - With reference to
FIGS. 1 and2 ,composite component 30 can includemetal alloy component 10, which has amain body 50 formed of a metal alloy. In some case, the metal alloy can include a brazeable alloy, such as a high-gamma prime alloy or a brittle alloy. In various embodiments, alloys having a gamma prime percentage greater than 40% can be well suited for approaches according to various embodiments of the disclosure, as these alloys can present challenges in welding. Examples are gamma prime (γ') precipitation-strengthened nickel-base superalloys, particular examples of which can include René 125,René 80, René N5, René N4, René 108, GTD-111™, GTD-444™, Inconel (IN)738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, and PWA1484. Each of these alloys has a relatively high gamma prime (principally Ni3(Al,Ti)) content as a result of containing significant amounts of aluminum and/or titanium. As noted herein, these metal alloys can be particularly susceptible to structural weakening under particular heat treatments such as welding, and may also be susceptible to failure or undesirable wear under tensile stress. As such, the configuration ofcomposite component 30 may help to transfer tensile stress to shear stress proximate braze joint 40. In some embodiments,coupon 20 includes the same metal alloy asmetal alloy component 10, or a distinct metal alloy. In some cases, thecoupon 20 can include a metal alloy which is more ductile than the alloy inmetal alloy component 10. In various embodiments,coupon 20 can be formed of (single-crystal, or SD) René N5, (directionally solidified, or DS) René 108, and/or (N4) or (Equiaxed, or EA) René 108. - With continuing reference to
FIGS. 1-3 ,main body 50 can have awall 60 with aninner surface 70 and an (opposed)outer surface 80. In some cases,inner surface 70 andouter surface 80 are merely indicative that these are distinct surfaces proximate braze joint 40 andcoupon 20, as the terms "inner" and "outer" are not intended to be limiting.Main body 50 can also include aslot 90 extending at least partially through wall 60 (shown extending entirely throughwall 60 in example depiction ofFIG. 1 ). As shown inFIG. 1 , slot 90 can include an angled main body interface (face) 100 inwall 60, described further herein. -
Composite component 30 includescoupon 20 coupled withslot 90, wherecoupon 20 has an angled coupon interface (face) 110 that complements angledmain body interface 100. Angled coupon interface (face) 110 can span between anouter surface 120 and aninner surface 130 ofcoupon 20. According to the invention as herein claimed, the angle ofangled coupon interface 110 is equal or approximately (e.g., within margin of measurement error) equal with the angle of angledmain body interface 100, both referred to as angle (α), as measured from a plane (P) coincident withouter surface 80 ofmain body 50. As shown inFIGS. 1 and2 ,coupon 20 can have a taper, such that it has a larger dimension (LD) spanningslot 90 acrossouter surface 80, and a smaller dimension (SD) spanningslot 90 acrossinner surface 70. In embodiments LD is defined by: - Wherein Z = a thickness of
wall 60. In some cases, angle (α) is between approximately 10 degrees and approximately 60 degrees. However, in other particular embodiments, angle (α) is between approximately 10 degrees and approximately 25 degrees. In other cases, angle (α) is between approximately 25-35 degrees, and in other cases angle (α) is between approximately 35-45 degrees. As noted herein, the angle (α) is designed for these particular metal alloys such that proximate braze joint 40, angledmain body interface 100 andangled coupon interface 110 are configured to bear a predominately shear stress in response to application of tension oncomposite component 30. In some cases,composite component 30 can include a turbomachine component, such as a combustion component or a gas or steam turbine component. -
FIG. 3 shows a flow diagram illustrating processes in a method according to various embodiments.FIGS. 4 and5 illustrate some of the processes described with reference toFIG. 3 . In various embodiments, a method can include: - Process P1: forming
slot 90 inmain body 50 of ametal alloy component 10, whereslot 90 is formed to extend at least partially through wall 60 (FIGS. 4 and5 ). In various embodiments, formingslot 90 includes forming angledmain body interface 100 inwall 60. In various embodiments,metal alloy component 10 can include a previously commissioned component exposed to operation within a machine, e.g., a turbomachine, dynamoelectric machine or other machine. In some cases,metal alloy component 10 includes a turbine bucket, blade or nozzle. It is understood thatmetal alloy component 10 can include any machine component, in any of a variety of industrial or other machines subjected to high temperatures and/or pressures, e.g., turbomachines, dynamoelectric machines, or engine systems. In other embodiments,metal alloy component 10 can include an original equipment component not yet deployed in operation. In some particular cases, formingslot 90 inmain body 50 includes cuttingmetal alloy component 10, e.g., with a saw or other machining tool. In other cases,metal alloy component 10 can be formed as an original component, includingslot 90, via conventional molding, casting, etc., or via additive manufacturing techniques further described herein. - Process P2: forming
coupon 20 for coupling withslot 90 inmetal alloy component 10, wherecoupon 20 is formed having angledcoupon interface 110 that complements angledmain body interface 100 in metal alloy component 10 (coupon 20 shown inFIG. 1 ). In some cases,coupon 20 is formed by casting or other conventional manufacturing techniques, and in other embodiments,coupon 20 is formed by additive manufacturing techniques further described herein. In various embodiments,coupon 20 includes a metal alloy, e.g., a metal alloy similar to the composition ofmetal alloy component 10, or a distinct metal alloy. As noted herein, angledmain body interface 100 andangled coupon interface 110 is formed to have angle (α) between approximately 10 degrees and approximately 45 degrees, as measured from plane (P) coincident withouter surface 80 ofmain body 50. It is understood thatcoupon 20 andslot 90 can be formed to have a range of angles (α), larger dimensions (LD) and smaller dimensions (SD), depending upon the thickness (Z) ofwall 60. In various embodiments, dimensions (LD, SD) will be dictated in part by a portion ofmetal alloy component 10 which requires repair. For example, wheremetal alloy component 10 is in need of repair, a portion ofmetal alloy component 10 is removed (e.g., cut out), andslot 90 is formed to accommodatecoupon 20. In these cases, the dimensions of diameters, along with thickness (Z) ofwall 60, will limit the range of interface angles (α). - Process P3: after forming
coupon 20 andslot 90, this process can includebrazing coupon 20 tomain body 50 atslot 90 to form composite component 30 (FIG. 2 ). In various embodiments, conventional brazing techniques can be used to form braze joint 40 along angledmain body interface 100 andangled coupon interface 110. In various embodiments the brazing temperature may range between approximately 925 degrees Celsius (C) (approximately 1700 degrees Fahrenheit (F)) and 1260 degrees C (approximately 2300 degrees F). In some particular cases, the brazing temperature may range between approximately 1065 degrees C (approximately 1950 degrees F) and approximately 1230 degrees F (approximately 2250 degrees F). In some cases, the thickness of the braze joint can be between approximately 0.0025 millimeters (mm) (approximately 0.1 mils) and approximately 1.27 millimeters (approximately 0.05 inches or approximately 2 mils). In some particular cases, the thickness of the braze joint can be approximately 0.025 millimeters (mm) (approximately 1 mil) to approximately 0.1 mm (approximately 4 mils). As noted herein, the angledmain body interface 100 andangled coupon interface 110, proximate (e.g., contacting or nearly contacting braze joint 40) are configured to bear a predominately shear stress in response to application of tension oncomposite component 30. - In some particular cases, after forming
composite component 30, an additional process can include performing a hot isostatic pressure (HIP) heat treatment (HT) oncomposite component 30. This HIP HT can occur after brazingcoupon 20 tomain body 50 atslot 90. This HIP HT can include any conventional HIP process known in the art, including the use of an inert gas (e.g., argon) at an elevated temperature (e.g., up to approximately 1,400 degrees C) and pressure (e.g., up to approximately 300 mega-pascals (MPa)) to reduce the porosity/increase the density ofcomposite component 30. - It is understood that the processes described herein can be performed in any order, and that some processes may be omitted, without departing from the spirit of the disclosure described herein.
- While the embodiment of
composite component 30 inFIGS. 1 and2 shows asingle coupon 30, it is understood thatcomposite component 30 can include a plurality ofcoupons 20 which may combine to fillslot 90 according to various embodiments of the disclosure. That is, while asingle coupon 20 is shown inFIGS. 1 and2 , it is understood that two ormore coupons 20 can be formed in order to fillslot 90 incomposite component 30. In some cases, a pair of coupons (e.g., similar to coupon 20) can be coupled withmain body 50 atslot 90, e.g., one from each ofinner surface 70 andouter surface 80. In these cases, the pair of coupons could share approximately the same shorter diameter (SD) value, their longer diameter (LD) value may be slightly different due to the geometry ofcomposite component 30. These coupons could be coupled with one another, and/ormain body 50, with one or more braze joints 40. - In additional embodiments, forming
slot 90 inmain body 50 can include forming one ormore slots 90 from two distinct directions throughwall 60. That is, in various embodiments, one ormore slots 90 may be formed in main body 50 (as described herein) from one or more surfaces (e.g.,inner surface 70, outer surface 80). For example, as shown in the schematic depiction of ametal alloy component 210 inFIGS. 6 and 7 ,slots 90 can be formed (as described herein) from opposing surfaces (e.g.,inner surface 70 and outer surface 80), and a plurality of coupons 20 (FIG. 6 ) can be formed (as described herein) to couple with slot(s) 90 and form a composite component 230 (FIG. 8 ). In some cases, two coupons 20 (FIG. 6 ) are formed to couple withslots 90 on opposing sides (e.g.,inner surface 70 and outer surface 80) ofmetal alloy component 110.Coupons 20 can be coupled withslots 90 as discussed herein to form another embodiment of a composite component. In various embodiments, where twoslots 90 are formed from opposing surfaces, thoseslots 90 may connect to form anaperture 250 throughmetal alloy component 210, however, in other embodiments, theseslots 90 may remain separated by a portion ofwall 60. In various embodiments,distinct slots 90 can have distinct dimensions (e.g., as governed by Equation 1), however, in other cases,distinct slots 90 can be substantially symmetrical with respect towall 60. In these embodiments, e.g., with twodistinct slots 90 throughopposite surfaces wall 60, the larger diameter (LD) can be reduced relative to the larger diameter (LD) incomposite component 30, which permitscomposite component 230 to have a lesser interface angle (α) (relative to composite component 30), while still being configured to bear a predominately shear stress in response to application of tension oncomposite component 230. - One or more portions of composite component 30 (
FIG. 2 ) and/or composite component 230 (FIG. 8 ) may be formed in a number of ways. In one embodiment, as noted herein, at least a portion ofcomposite component 30 may be formed by conventional manufacturing techniques, such as molding, casting, machining (e.g., cutting), etc. In one embodiment, however, additive manufacturing is particularly suited for manufacturing at least a portion of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ), e.g.,metal alloy component 10,metal alloy component 210 and/orcoupon 20. As used herein, additive manufacturing (AM) may include any process of producing an object through the successive layering of material rather than the removal of material, which is the case with conventional processes. Additive manufacturing can create complex geometries without the use of any sort of tools, molds or fixtures, and with little or no waste material. Instead of machining components from solid billets of metal (e.g., alloy) or other material such as plastics and/or polymers, much of which is cut away and discarded, the only material used in additive manufacturing is what is required to shape the part. Additive manufacturing processes may include but are not limited to: 3D printing, rapid prototyping (RP), direct digital manufacturing (DDM), selective laser melting (SLM) and direct metal laser melting (DMLM). In the current setting, DMLM can be beneficial. - To illustrate an example of an additive manufacturing process,
FIG. 9 shows a schematic/block view of an illustrative computerizedadditive manufacturing system 900 for generating anobject 902. In this example,system 900 is arranged for DMLM. It is understood that the general teachings of the disclosure are equally applicable to other forms of additive manufacturing.Object 902 is illustrated as a double walled turbine element; however, it is understood that the additive manufacturing process can be readily adapted to manufacture at least a portion of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ), e.g.,metal alloy component 10,metal alloy component 110 and/orcoupon 20.AM system 900 generally includes a computerized additive manufacturing (AM)control system 904 and anAM printer 906.AM system 900, as will be described, executescode 920 that includes a set of computer-executable instructions defining at least a portion of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ) to physically generate the object usingAM printer 906. Each AM process may use different raw materials in the form of, for example, fine-grain powder, liquid (e.g., polymers), sheet, etc., a stock of which may be held in achamber 910 ofAM printer 906. In the instant case, at least a portion of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ) may be made of metal(s), alloy(s), plastic/polymers or similar materials. As illustrated, anapplicator 912 may create a thin layer ofraw material 914 spread out as the blank canvas from which each successive slice of the final object will be created. In other cases,applicator 912 may directly apply or print the next layer onto a previous layer as defined bycode 920, e.g., where the material is a polymer. In the example shown, a laser orelectron beam 916 fuses particles for each slice, as defined bycode 920, but this may not be necessary where a quick setting liquid plastic/polymer is employed. Various parts ofAM printer 906 may move to accommodate the addition of each new layer, e.g., abuild platform 918 may lower and/orchamber 910 and/orapplicator 912 may rise after each layer. -
AM control system 904 is shown implemented oncomputer 930 as computer program code. To this extent,computer 930 is shown including amemory 932, aprocessor 934, an input/output (I/O)interface 936, and abus 938. Further,computer 930 is shown in communication with an external I/O device/resource 940 and astorage system 942. In general,processor 934 executes computer program code, such asAM control system 904, that is stored inmemory 932 and/orstorage system 942 under instructions fromcode 920 representative of at least a portion of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ), described herein. While executing computer program code,processor 934 can read and/or write data to/frommemory 932,storage system 942, I/O device 940 and/orAM printer 906.Bus 938 provides a communication link between each of the components incomputer 930, and I/O device 940 can comprise any device that enables a user to interact with computer 940 (e.g., keyboard, pointing device, display, etc.).Computer 930 is only representative of various possible combinations of hardware and software. For example,processor 934 may comprise a single processing unit, or be distributed across one or more processing units in one or more locations, e.g., on a client and server. Similarly,memory 932 and/orstorage system 942 may reside at one or more physical locations.Memory 932 and/orstorage system 942 can comprise any combination of various types of non-transitory computer readable storage medium including magnetic media, optical media, random access memory (RAM), read only memory (ROM), etc.Computer 930 can comprise any type of computing device such as a network server, a desktop computer, a laptop, a handheld device, a mobile phone, a pager, a personal data assistant, etc. - Additive manufacturing processes begin with a non-transitory computer readable storage medium (e.g.,
memory 932,storage system 942, etc.) storingcode 920 representative of at least a portion of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ). As noted,code 920 includes a set of computer-executable instructions defining outer electrode that can be used to physically generate the tip, upon execution of the code bysystem 900. For example,code 920 may include a precisely defined 3D model of outer electrode and can be generated from any of a large variety of well-known computer aided design (CAD) software systems such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc. In this regard,code 920 can take any now known or later developed file format. For example,code 920 may be in the Standard Tessellation Language (STL) which was created for stereolithography CAD programs of 3D Systems, or an additive manufacturing file (AMF), which is an American Society of Mechanical Engineers (ASME) standard that is an extensible markup-language (XML) based format designed to allow any CAD software to describe the shape and composition of any three-dimensional object to be fabricated on any AM printer.Code 920 may be translated between different formats, converted into a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as necessary.Code 920 may be an input tosystem 900 and may come from a part designer, an intellectual property (IP) provider, a design company, the operator or owner ofsystem 900, or from other sources. In any event,AM control system 904 executescode 920, dividing at least a portion of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ) into a series of thin slices that it assembles usingAM printer 906 in successive layers of liquid, powder, sheet or other material. In the DMLM example, each layer is melted to the exact geometry defined bycode 920 and fused to the preceding layer. Subsequently, the portion(s) of composite component 30 (FIG. 2 ) and/or composite component 230 (FIG. 8 ) may be exposed to any variety of finishing processes, e.g., minor machining, sealing, polishing, assembly to other part of the igniter tip, etc. - This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems.
Claims (9)
- A method comprising:forming a slot (90) in a main body (50) of a metal alloy component (10, 210), the slot (90) extending at least partially through a wall (60) of the metal alloy component (10, 210);forming a coupon (20) for coupling with the slot (90) in the metal alloy component (10, 210); andbrazing the coupon (20) to the main body (50) at the slot (90) to form a composite component (30, 230),characterized in that the forming of the slot (90) including forming an angled main body interface (100) in the wall (60) of the metal alloy component (10, 210) having an angle (α) between approximately 10 degrees and approximately 45 degrees, as measured from a plane coincident with an outer surface (80) of the main body (50) and forming the coupon (20) includes forming the coupon (20) with an angled coupon interface (110) complementing the angled main body interface (100).
- The method of claim 1, wherein the metal alloy component (10, 210) includes a high-gamma prime alloy or a brittle alloy including: René 125, René 80, René N5, René N4, René 108, GTD-111, GTD-444, Inconel (IN) 738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, or PWA1484.
- The method of claim 1 or claim 2, wherein the metal alloy component (10, 210) is a previously commissioned component exposed to operation within a machine.
- The method of any preceding claim, wherein the angled main body interface (100) and the angled coupon interface (110) have an angle between approximately 10 degrees and approximately 25 degrees, as measured from a plane coincident with an outer surface (80) of the main body (50).
- The method of any preceding claim, wherein the forming of the slot (90) in the main body (50) includes cutting the metal alloy component (10, 210), and wherein forming the coupon (20) includes casting or additively manufacturing the coupon (20).
- The method of any preceding claim, wherein the main body (50) has an outer surface (80) and an inner surface (70), wherein forming of the slot (90) includes forming the slot extending through the wall (60) of the metal alloy component (10, 210), and the coupon (20) has:a larger diameter (LD) spanning the slot (90) across the outer surface (80) of the main body (50); andwherein Z = a thickness of the wall (60) and α = an angle of the angled main body interface (100) and the angled coupon interface (110), as measured relative to a plane coincident with the outer surface (80) of the main body (50).
- The method of any preceding claim, wherein the angled main body interface (100) and the angled coupon interface (110) are configured to bear a predominately shear stress in response to application of tension on the composite component (30, 230).
- The method of any preceding claim, wherein the composite component (30, 230) includes a turbomachine component.
- A composite component (30, 230) comprising:a metal alloy component (10, 210) including a main body (50), the main body (50) having:a wall (60) having an inner surface (70) and an outer surface (80); anda slot (90) extending through the wall (60), the slot (90) including an angled main body interface (100) in the wall (60);a coupon (20) coupled with the slot (90), the coupon (20) having an angled coupon interface (110) complementing the angled main body interface (100), wherein the coupon (20) has a larger diameter (LD) spanning the slot (90) across the outer surface (80) of the main body (50); and a smaller diameter (SD) spanning the slot (90) across an inner surface (70) of the main body (50), wherein the LD is defined (3D) by:wherein Z = a thickness of the wall (60) and α = an angle of the angled main body interface (100) and the angled coupon interface (110), as measured from a plane coincident with the outer surface (80) of the main body (50); anda braze joint (40) coupling the coupon (20) to the main body (50) at the slot (90) characterized in that the angle (α) of the angled main body interface (100) and the angled coupon interface (110) as measured from a plane coincident with an outer surface (80) of the main body (50) is between approximately 10 degrees and approximately 45 degrees.
Applications Claiming Priority (1)
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US15/605,294 US10456849B2 (en) | 2017-05-25 | 2017-05-25 | Composite component having angled braze joint, coupon brazing method and related storage medium |
Publications (2)
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EP3406382A1 EP3406382A1 (en) | 2018-11-28 |
EP3406382B1 true EP3406382B1 (en) | 2021-05-05 |
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EP (1) | EP3406382B1 (en) |
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CN (1) | CN108959701B (en) |
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2017
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-
2018
- 2018-05-23 EP EP18173747.9A patent/EP3406382B1/en active Active
- 2018-05-24 KR KR1020180058916A patent/KR102543860B1/en active IP Right Grant
- 2018-05-25 CN CN201810513529.1A patent/CN108959701B/en active Active
- 2018-05-25 JP JP2018100269A patent/JP7250437B2/en active Active
-
2019
- 2019-07-10 US US16/507,349 patent/US20190329344A1/en not_active Abandoned
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KR20180129670A (en) | 2018-12-05 |
JP2019000905A (en) | 2019-01-10 |
US20180339354A1 (en) | 2018-11-29 |
US10456849B2 (en) | 2019-10-29 |
JP7250437B2 (en) | 2023-04-03 |
KR102543860B1 (en) | 2023-06-14 |
CN108959701A (en) | 2018-12-07 |
US20190329344A1 (en) | 2019-10-31 |
EP3406382A1 (en) | 2018-11-28 |
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